INTRODUCTION
The present invention relates generally to footwear, more particularly, to a shoe assembly having a detachable shoe cover and base that permits customizing the shoe to various tastes, occasions, and functions.
There have long been many varieties and configurations of shoes. A limitation of traditional shoes is that the upper cover and the base are permanently interconnected, or might be a single integral part, which cannot be altered so that only one permanent style is provided. In addition, with the upper cover and the base being permanently interconnected, inner surfaces of the shoes, particularly in the toe box area, are difficult to clean and are difficult to dry if the shoes become wet.
U.S. Pat. No. 4,745,693 to Brown discloses a zipper having slide means to attach the upper and sole of the shoe together. However, two halves of the zipper require to be matched in size and length in order to properly connect the upper and the sole. In addition, the zipper can be easily damaged, resulting in a complete scrapping of the shoe and being expensive to repair. Moreover, the shoe using the zipper means to attach the upper and sole has relatively poor waterproofing functionality and it is difficult to physically seal footwear from water. In addition, when the uppers gets dirty and stained, there are no effective means of cleaning them thoroughly and efficiently.
U.S. Pat. No. 5,065,531 to Prestridge discloses a shoe having an upper portion and a sole-and-toe portion releasably joined together by a male/female track attachment device. The upper portion is designed to be attached to an existing shoe structure. The approaches by Prestridge are difficult to implement in practice due to bending of the shoe and particularly bending of the upper during use.
SUMMARY OF THE INVENTION
The present invention provides a base of a shoe and an easily interchangeable cover for the base so that the user can quickly and easily assemble a shoe, i.e., shoe assembly, and create a variety of different shoe configurations and styles. The present invention also provides a shoe assembly with a stable and mechanically secure structural configuration when the shoe base and the cover are in their assembled state, and further provides a continuous seal around the periphery of shoe for weather protection. Moreover, the shoe assembly, including the base and interchangeable cover(s), of the present invention are inexpensive to manufacture. Specifically, the present invention provides the detachable/interchangeable shoe cover and shoe base structures in which the shoe cover and the shoe base can be independently exchanged and matched in a simple, fast, and secure manner.
In accordance with the present invention, the shoe assembly comprises a base portion including a sole and a first engaging portion, an upper cover portion separately formed from the base portion and including a shoe upper and a second engaging portion configured to engage with the first engaging portion to releasably couple the upper cover portion to the base portion, and a fastening assembly configured to further secure the releasable coupling between the upper cover portion and the base portion, wherein a force applied by the fastening assembly to the releasable coupling is adjustable, e.g., by a user. In some embodiments, the first engaging portion extends around at least a portion of a midsole of the base portion, and the second engaging portion extends around at least a portion of a lower periphery of the shoe upper.
In some embodiments, the first engaging portion comprises at least one first recess formed on an outer surface of the base portion, and the second engaging portion comprises at least one projection formed on an inner surface of the upper cover portion and at least one second recess formed on an outer surface of the upper cover portion corresponding in position to the at least one projection, and the at least one projection on the inner surface of the upper cover portion is configured to engage with the at least one first recess formed on the outer surface of the base portion. In such embodiments, the at least one second recess receives the fastening assembly, and the fastening assembly secures the releasable coupling by applying a compressive force to the at least one second recess.
In some embodiments, the base portion further comprises an anchor for anchoring the fastening assembly to the base portion. The anchor may be formed on an outsole portion of the sole. In certain embodiments, the fastening assembly comprises at least one cable configured to pass through the at least one second recess so as to apply a compressive force to the at least one second recess and further configured to engage with the anchor. The fastening assembly may also include at least one retaining member for retaining the at least one cable within the at least one second recess. In certain embodiments, the at least one retaining member comprises at least one tube configured to fit firmly and securely within at least one second recess and has an elongated opening for passing the at least one cable therethrough.
In certain embodiments, the shoe assembly further comprises an anchor for anchoring the fastening assembly to the base portion. In some illustrative embodiments, the anchor is removably attached to an outsole of the base portion. For example, the anchor may protrude from a waist portion of an outsole of the base portion.
In some embodiments of the shoe assembly, the first engaging portion comprises at least one first recess formed on an outer surface of the base portion and at least one projection formed on an inner surface of the base portion corresponding in position to the at least one first recess, and the second engaging portion comprises at least one second recess formed on an outer surface of the upper cover portion, wherein the at least one projection on the base portion is configured to engage with the at least one second recess formed on the outer surface of the upper cover portion.
In accordance with the present embodiment, a shoe assembly is provided, with the shoe assembly comprising a base portion including a sole and an engaging portion, an upper cover portion separately formed from the base portion and including a shoe upper and at least one lower extension extending from a lower edge of the shoe upper, and a fastening assembly provided on the lower extension of the upper cover portion and configured to releasably couple with the engaging portion of the base portion. In some embodiments, the engaging portion comprises at least one elongated recess formed around at least a portion of a midsole of the base portion and the fastening assembly is provided on an inner surface of the upper cover portion. In such embodiments, the lower extension of the upper cover portion overlaps with at least a portion of the midsole of the base portion when the fastening assembly is releasably coupled with the at least one elongated recess.
In some embodiments, the fastening assembly comprises at least one elongated tube configured to fit firmly and securely within the at least one elongated recess in the base portion. In certain embodiments, the shoe assembly also includes an anchor formed on the base unit, and the fastening assembly is further configured to secure the releasable coupling between the fastening assembly and the engaging portion to the anchor. In some embodiments, the fastening assembly is configured to apply a compressive force to the releasable coupling between the fastening assembly and the engaging portion, and the amount of compression applied may be adjustable by a user. In yet other embodiments, the fastening assembly is configured to seal an interface between the lower extension and the base portion.
In some illustrative configurations of the shoe assembly, the at least one lower extension includes a rear lower extension extending from a lower edge of a heel portion of the shoe upper and a front lower extension extending from a lower edge of a toe portion of the shoe upper. In other configurations, the at least one lower extension extends around the entire lower edge of the shoe upper.
A shoe upper for use in a shoe assembly and configured to releasably engage with a base portion of the shoe assembly is also described. Different shoe uppers can be interchangeably connected to the base portion to create new shoe assembly configurations.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and aspects of the present invention will become more apparent upon reading the following detailed description in conjunction with the accompanying drawings, in which:
FIGS. 1A-1B show a shoe assembly of the present invention in an assembled state and an exploded state;
FIGS. 2A-2D show a first embodiment of a base unit of the shoe assembly of the present invention, without an upper cover unit attached thereto;
FIGS. 3A-3D show a second embodiment of the base unit of the shoe assembly of the present invention;
FIGS. 4A-4B show a first embodiment of the upper cover unit of the shoe assembly of the present invention, and configured to attach to the base unit of FIGS. 2A-2D or the base unit of FIGS. 3A-3D;
FIGS. 5A-5B show application of an assembly unit to assembled upper cover unit and base unit;
FIGS. 6A-6B show a second embodiment of the upper cover unit of the shoe assembly of the present invention;
FIG. 6C shows the upper cover unit of FIGS. 6A-6B and an assembly unit for securing the upper cover unit to a base unit;
FIG. 6D shows the upper cover unit of FIGS. 6A-6C with the assembly unit attached thereto; and
FIGS. 7A-7B show an alternative embodiment of the upper cover unit of the shoe assembly of the present invention.
DETAILED DESCRIPTION
As shown in FIGS. 1A-7B shown and described herein below, the shoe assembly of the present invention generally comprises at least a base unit 100, an upper cover unit 200 and an assembly unit 300. The upper cover unit 200 and the base unit 100 are removably adaptable and attachable to each other via adapting structures constructed in corresponding locations of the upper cover unit 200 and the base unit 100. The upper cover unit 200 and base unit 100, after being attached to one another via the adapting structures, are further secured together by applying the assembly unit 300. Details of each component of the shoe assembly and methods of assembling the same are described in detail below.
In the detailed description which follows, the features of the present invention described below are applicable to a pair of shoes, or a pair of shoe assemblies, that include a right and a left shoe/shoe assembly. However, the following descriptions are only made with respect to the right shoe assembly for clarity and conciseness. Though the structure of the left shoe assembly is omitted here, it should be apparent to those skilled in the art based on the descriptions of the right shoe assembly which uses the same or substantially similar components and assembly mechanisms.
The Shoe Assembly
FIGS. 1A-1B show an illustrative embodiment of the shoe assembly of the present invention. FIG. 1A shows the shoe assembly in an assembled state while FIG. 1B shows an exploded view of the shoe assembly. As shown in FIGS. 1A-1B, the shoe assembly includes the base unit 100 which forms a sole of the assembled shoe and the upper cover unit 200 which forms the upper of the assembled shoe.
The base unit 100 and the upper cover unit 200 are configured to releasably engage with one another via adapting structures, and as described in more detail below, using structures of corresponding male-female shapes to engage with one another. As can be seen in FIGS. 1A-1B, a lower portion of the upper cover unit 200 is positioned over to overlap with, and engages with, an upper portion of the base unit 100. Different embodiments of the base unit 100 and the upper cover unit 200 are shown in FIGS. 2A-4B and FIGS. 6A-7B and described in more detail below.
In addition, one or more assembly units 300, each including a cable or a cord 340 and/or a tube 320 partially enclosing the cord 340, are used for further securing the upper cover unit 200 to the base unit 100 so as to reduce the risk of disengagement during use and to improve impermeability of the shoe assembly to liquids from the outside. In FIGS. 1A-1B, the shoe assembly includes two assembly units 300, each including the cable or cord 340 threaded through the tube 320, and the tube 320 is fitted within an external recess formed by an engaging groove 280 in the upper cover unit 200. In FIGS. 1A-1B, the assembly units 300 are shown as engaged with the upper cover unit 200, but it is understood that in certain embodiments, the assembly units 300 are removable from the upper cover unit 200, while in other embodiments the tube 320 of each assembly unit 300 may be permanently attached or integrally formed with the upper cover unit.
As described in more detail below, the assembly unit 300 can be adjustable to adjust the amount of anchoring of the upper cover unit 200 to the base unit 100, and how tightly the upper cover unit 200 is coupled to the base unit 100. The assembly unit 300 is described in more detail below with respect to FIGS. 2A-2D and 5A-5B.
The Base Unit
FIGS. 2A-2D illustrate an embodiment of a base unit 100 of the shoe assembly, before an upper cover unit is attached thereto.
As illustrated in FIG. 2A, the base unit 100 of the present embodiment includes a sole, forming an outsole and at least a portion of a midsole, and comprises a top surface 100a and a tough and wear resistant bottom surface 100b of the outsole for providing traction against the ground or floor. The top surface 100a of the base unit 100 may be substantially smooth or may include a 3-dimensional pattern or tread (e.g., in-molded pattern) on at least a portion thereof to provide a gripping surface for use with insoles or the like, or for provide a gripping surface for the user's foot. In some embodiments, the base unit 100 may include an insole permanently or removably attached to the top surface or incorporated into the top surface 100 thereof.
The base unit 100 has a forefoot portion 120, a heel portion 160 and a midfoot portion 140 disposed between the forefoot portion 120 and the heel portion 160. The midfoot portion 140 in the present embodiment includes the waist portion of the sole and the base unit. In the illustrative embodiment shown in FIGS. 2A and 2B, the material of the midfoot portion 140 has a smaller thickness than the material of the forefoot portion 120 and the heel portion 160 to permit greater flexibility and stretchability. However, in other variations, thicknesses of the forefoot portion, midfoot portion and heel portion may vary depending on the style, rise from front to back and other requirements of the shoe. For example, in a heeled shoe, the heel portion may have greater thickness than both the forefoot and midfoot portions. In another example, in an athletic style shoe, the thickness of the forefoot portion may be smaller than the thickness of the midfoot portion and of the heel portion, or in some athletic shoes, the thickness of the forefoot and heel portions may be substantially the same while the midfoot portion has a smaller or the same thickness.
As shown in FIG. 2A, the base unit 100 further comprises an engaging groove or channel 180 recessed into the interior area and extending around at least a portion of the sole periphery. As shown, the engaging groove 180 extends along at least a portion of the midsole periphery of the base unit 100, and in some embodiments, the engaging groove 180 extends along the entire periphery of the midsole of the base unit 100. The engaging groove 180, as an adaptable structure of the base unit 100, is constructed engaged with a projection or protrusion formed by an engaging groove 280 (will be described later) of the upper cover unit 200 in order to attach the upper cover unit 200 onto the base unit 100. The engaging groove 180 of the base unit 100 forms a female portion of the coupling between the base unit 100 and the upper cover unit 200 while the projection or protrusion of the corresponding engaging groove 280 of the upper cover unit 200 forms a male portion of the coupling.
In the embodiment illustrated in FIGS. 2A-2C, the engaging groove 180 of the base unit 100 extends along substantially the entire periphery of the base unit 100. In the example shown, when the base unit 100 is placed on a support surface, the engaging groove 180 is oriented substantially horizontally relative to the support surface in the forefoot portion 120 and in the heel portion 160 of the base unit and slopes at a predetermined angle relative to a horizontal plane of the support surface in the midfoot portion 140 (this is due to the differences in the thickness between the forefoot portion 120 and the heel portion 160). However, the heights, widths, and inclines, as well as the thickness of the base unit 100 may be varied depending on the sole requirements and depending on the area of the sole.
In the embodiments as shown in FIGS. 2A-2C, the engaging groove 180 is substantially continuous around the periphery of the midsole. However, in yet another embodiment, the engaging groove 180 may be continuous around the forefoot portion 120 and the heel portion 160 of the midsole periphery but may be interrupted at the midfoot portion of the base unit 100 (i.e., with no engaging groove being provided at the midfoot portion).
The outsole of the illustrative base unit 100, in the shown embodiment, has a tread pattern offering good anti-slip characteristics and preventing slips on smooth surfaces like ice, snow, wet floors and the like. The base unit 100 may also include ventilation holes to make the shoe breathable, lightweight, and comfortable to wear. The style of the outsole and the surface texture of the outsole of the base unit may be varied depending on the style of the shoe.
In the embodiments shown in FIG. 2A-2D, the midfoot portion 140 is structured to be thinner than the forefoot portion 120 and the heel portion 160, forming a recessed area between the forefoot and heel portions. As shown in FIG. 2D, a fastening unit 190 for anchoring the assembly unit 300, described in more detail below, is provided in the recessed area of the midfoot portion 140 of the base unit 100. According to one exemplary embodiment of the present embodiment, the fastening unit is an anchor 190, which includes one or more projections projecting from the bottom surface, i.e., from the outsole, of the midfoot portion. The anchor 190 extends from and/or is attached to the bottom surface or outsole of the midfoot portion 140 of the base unit 100, and in some embodiments, to the waist portion of the outsole.
In the embodiment as shown in FIG. 2D, the anchor 190 has a transverse projection (not visible) that projects from the bottom recessed surface of the midfoot portion 140, and in certain embodiments, from a waist portion of the outsole of the base unit. The anchor includes an anchoring end at the end of the transverse projection, which preferably has a larger span/size than the transverse projection. In the embodiment of FIG. 2D, the anchoring end has an “X” or cross shape, with 4 arms extending in different directions in a plane substantially parallel to the bottom surface of the outsole. As shown in FIG. 2D, a string or cable 340 is attached to the anchor 190 and the 4 arms of the anchoring end are used for securing the string to the base unit. The X-shaped anchoring end of the anchor 190 is particularly suitable for securely fastening the string or cable 340 to the anchor 190, especially with the ends of the string or cable 340 being attached from different directions, and for preventing disengagement of the string or cable 340 therefrom. However, it is understood that the anchor 190 can have other shapes, e.g., including shapes with multiple arms or one or more hooks or one or more loops, as long as a string, a tube, a cable or another suitable tether, can be affixed or fastened firmly thereto without risking disengagement therefrom. For example, in some embodiments, the anchor 190 may include a clip or a clasp or another type of fastener for securing the string or cable or tether thereto. In yet other embodiments, other fasteners, such as hooks (e.g., metallic or plastic hooks) and/or eyelets or loops for engaging with hooks or other fasteners may be provided on the sole to enable the string or cable or other type of tether or connector to engage therewith.
In addition, as shown in FIGS. 2A and 2D, which are the respective side view and the bottom view of the base unit 100, four guides 181, 182, 183 and 184 are formed as guiding recesses in the midfoot portion 140 for guiding the assembly unit 300, and in particular the string or cable 340 of the assembly unit, from the engaging groove 180 of the base unit to the anchor 190. Specifically, each of the four guides 181, 182, 183 and 184 is a recess extending between the engaging groove 180 and the outsole of midfoot portion 140. In an embodiment where the engaging groove is interrupted in the midfoot portion, each of the four guides 181-184 extends from a respective end of the engaging groove 180 to the outsole of the midfoot portion 140, i.e., in the areas where the engaging groove discontinues. In the illustrative embodiment shown in FIG. 2D, in the right shoe of a user, the guides 181 and 182 are located on the medial side (or arch side) of the base unit corresponding to the inner portion of the user's foot and the guides 183 and 184 are located on the lateral or outer side of the base unit corresponding to the outer portion of the user's foot.
The four guides 181, 182, 183 and 184 are provided in the midfoot portion of the base unit for guiding the assembly unit 300 to the anchor 190 for fastening the upper cover unit to the base unit 100, after the upper cover unit is engaged with the base unit 100 as described in more detail below. As shown, each guide 181, 182, 183 and 184 is formed as a small groove or recess extending from the end of the engaging groove 180 inwardly toward the anchor 190 on the midfoot portion. The length of each guide 181, 182, 183, 184 may be limited to the area adjacent to the periphery of the midfoot portion, or in other embodiments may extend partially or entirely all the way to the anchor 190. In the embodiment shown, the guides 181-184 are recessed into the midfoot portion, while in other embodiments, a guiding channel configured to receive the string or cable 340 may be formed by one or more projections or hooks on the bottom surface of the midfoot portion. In some embodiments, one or more fasteners may be used instead of the recessed guides 181-184, including but not limited to clips, hooks, eyelets, clasps, etc., so as to temporarily attach, guide and/or hold in place the string or cable of the assembly unit when it is being fastened to the anchor 190.
It is noted that the string, cable or tether 340 in FIGS. 2A-2D is merely an example of an assembly unit 300 that can be applied to the engaging groove 180 of the base unit 100 and/or the engaging groove 280 of the upper cover unit and that can engage with the anchor 190 to secure the upper cover unit 200 to the base unit 100. As described in more detail below, in one exemplary embodiment of present invention, the string, cable or tether is applied to an engaging groove 280 of the upper cover unit 200 engaged with and cooperating with the engaging groove 180 of the base unit 100, after the upper cover unit 200 engages with the base unit 100. In one example, the string, cable or tether 340, after passing through a channel formed by the engaging groove 280 engaged with the engaging groove 180 in the forefoot portion 120, exits the engaging groove 280 at the midfoot portion 140 and passes through the guides 182 and 183, and then extends to the anchor 190 located on the bottom surface of the midfoot portion 140. In this way, the string, cable or tether 340 can be tightened and secured to the anchor 190, and the amount of tightening can be adjusted based on a user's preference.
Similarly, in the heel portion 160, the string, cable or tether 340 passes through the channel formed by the engaging groove 280 engaged with the engaging groove 180 in the heel portion 160 and exits the engaging groove 280 at the midfoot portion 140 and passes through the guides 181 and 184 and then extends to the anchor 190 so that the string, cable or tether 340 can be tightened and secured to the anchor 190. In this way, the tightening of the string, cable or tether adjusts the tension of the sting, cable or tether, thereby adjusting the amount of force applied by the assembly unit to the releasable coupling, i.e., the overlapping engaging grooves, between the upper cover unit and the base unit.
In the embodiments shown in the above FIGS. 2A, 2C and 2D, a single string, cable or tether 340 is used for securing both the forefoot portion 120 and the heel portion 160. However, in other embodiments, two separate strings, cables or tethers, or additional strings, cables or tethers may be used. For example, if two separate strings, cables or tethers are used, one string, cable or tether can be tightened around the engaging groove 280 in the forefoot portion 120 and the other string, cable or tether can be tightened around the engaging groove 280 in heel portion 160.
Moreover, in the embodiments shown in the above FIGS. 2A, 2C and 2D, the string, cable or tether is tightened to the anchor 190 by wrapping the string, cable or tether around the anchor and by tying one or more knots. However, other fastening methods, such as clips or hooks and eyelets or other suitable methods, or knot tying methods to prevent the string, cable or tether from loosening can be implemented. For example, in some embodiments the ends of each string, cable or tether may include one or more loops or eyelets or other fasteners that allow the ends of the string, cable or tether to be connected to the anchor 190 and to adjust the tension of the string cable or tether. By adjusting the tension of the string, cable or tether, the amount of force applied to the releasable coupling between the upper cover unit and the base unit is also adjusted.
In the embodiments shown in the above FIGS. 2A, 2C and 2D, the anchor 190 is permanently attached to the bottom surface of the base unit 100. However, in some embodiments, the anchor 190 can be removably attached, such as by clipping into or snapping into a corresponding receiving recess or projection, or by using suitable fasteners. In other embodiments, the base unit may not include a permanent anchor, and instead can have a removably attached cleat unit which includes an anchor for fastening and securing the assembly unit 300. Exemplary embodiments of such base unit with an attachable a cleat unit will be described below.
An Alternative Embodiment of the Base Unit
FIGS. 3A-3D illustrate an alternative embodiment of the base unit 100. A perspective view and a side view of the alternative base unit 100 of the shoe assembly without an upper cover unit being attached thereto, is shown in the following FIGS. 3A and 3B, respectively.
As illustrated in FIG. 3A, the base unit 100 of the present embodiment forms a shoe sole including an outsole and at least a portion of a midsole and including the top surface 100a and the bottom outsole surface 100b, which in this embodiments includes a tread for providing traction against the ground or floor.
As in the previous embodiment of the base unit, the base unit of FIGS. 3A and 3B includes the forefoot portion 120, the heel portion 160 and the midfoot portion 140 provided between the forefoot portion 120 and the heel portion 160. In this illustrative embodiment, the midfoot portion 140 has a smaller thickness than the forefoot portion 120 and the heel portion 160, to permit greater flexibility and stretchability. In addition, as shown in FIGS. 3A and 3B, the outsole or bottom surface of the midfoot portion 140 is recessed relative to the forefoot and heel portions.
The base unit 100 of FIGS. 3A and 3B comprises the engaging groove 180 which is recessed into the interior area of the sole periphery and forms a channel along the periphery, or at least a portion of the periphery, of the midsole. The engaging groove 180 is constructed to be adaptable to, and to engage with, a corresponding engaging groove 280 (will be described later) of on the upper cover unit 200, in order to attach the upper cover unit 200 to the base unit 100.
In this embodiment, a cleat unit 170 shown in FIGS. 3C and 3D can be releasably attached to the bottom surface/outsole surface of the base unit, in particular, in the midfoot portion 140 or in a vicinity of midfoot portion 140 of the base unit 100. In certain embodiments, the cleat unit 170 is releasably attached to a waist portion of the outsole of the sole, which is part of the midfoot portion 140. The cleat unit 170 is structured to accepting the assembly unit 300, in order to further secure the attachment of the upper cover unit and the base unit 100 and to provide an adjustable fit by tightening or loosening the assembly unit.
Specifically, the cleat unit 170 comprises a top surface 170a and an opposing bottom surface 170b. As shown in FIG. 2C, an anchor 190a extends from the opposing bottom surface 170b of the cleat unit 170. The anchor 190a includes a transverse projection 191 that projects or protrudes from the bottom surface 170 of the cleat unit 170 and an anchoring end 192 formed at the tip or end of the transverse projection 191. The anchoring end includes a plurality of arms extending in different directions relative to one another. The anchoring end may be formed as an X or cross shape, similar to the anchor 190 of FIGS. 1A-1D, or may include fewer or more arms. In some embodiments, the anchoring end may include one or more hooks or curved arms or one or more fasteners, such as clips, clasps, snaps, etc. The shape of the anchoring end 192 shown in FIG. 3C allows the assembly unit to be connected to the anchor 190a from different directions for a secure connection.
As shown in FIGS. 3C-3D, the top surface 170a of the cleat unit is configured as a contacting surface configured to contact with the bottom surface of the midfoot portion 140 of the base unit 100, and more specifically with the bottom surface/outsole of a waist portion of the sole. In certain embodiments, the top surface 170a of the cleat unit 170a is sized so as to contact a substantial majority of the midfoot portion so as to provide a stable connection.
In the illustrative embodiment of FIG. 3D, the cleat unit 170 further comprises a first side extension 1701 and a second side extension 1702 each of which protrudes outwardly from the top surface 170a of the cleat unit 170 along a respective side edge. The first side extension 1701 and the second side extension 1702 extend in a direction of a transverse arch of a user's foot, that runs from a medial side (or arch side) to a lateral side (outer side) of the user's foot. The combination of the first side extension 1701, the top surface 170a, and the second side extension 1702 forms a space for accommodating the midfoot portion 140 of the base unit 100. The cleat unit 170 of FIGS. 3C-3D is configured to attach to the midfoot portion 140 of the base unit 100 by abutting the first side extension 1701 to the medial side (or arch side) of the base unit 100 and abutting the second side extension 1702 to the lateral side of the base unit 100. When the cleat unit 170 is assembled with the base unit 100, the cleat unit 170 wraps around the midfoot portion 140 of the base unit, with the top surface abutting the outsole of the midfoot portion and the first and second side extensions 1701 and 1702 abutting the external surfaces of the midsole in the midfoot portion.
As can be seen in FIG. 3C, the cleat unit 170a also includes a third extension 1703 and a fourth extension 1704 protruding from the bottom surface 170b along respective front and rear edges of the cleat unit 170a. The third and fourth extensions 1703 and 1704 extend in an opposite direction from the first and second side extensions 1701, 1702 and are configured to abut a front sidewall of the heel portion and a rear sidewall of the forefoot portion, respectively, that form the rear and front edges of the midfoot portion.
The attachment of the cleat unit 170 to the midfoot portion 140 of the base unit may be accomplished by molding the side extensions 1701, 1702 to the shape of the midsole so as to tightly fit or to snap fit to the midsole of the midfoot region and/or by molding the side extensions 1703 and 1704 so as to tightly fit or snap fit to the sidewalls forming the front and rear edges of the midfoot portion. In some embodiments, no fasteners are required for attaching the cleat unit to the midfoot portion 140, while in other embodiments one or more fasteners or an adhesive may be used to promote attachment or to make the attachment more secure. In certain embodiments, a snap fit engagement of the cleat unit 170 to the midfoot portion 140 is accomplished by providing one or more projections and/or recesses on each of the side extensions 1701-1704 and by providing one or more corresponding recesses and/or projections on the exterior surfaces of the midsole and front and rear sidewalls of the respective heel and forefoot portions so that each projection engages with a corresponding recess when the cleat unit 170 is snap fit to the midfoot portion 140.
After the cleat unit 170 is attached to the base unit 100, the anchor 190a located on the cleat unit 170 is ready for accepting the assembly unit 300 for fastening and securing the upper cover unit to the base unit 100. Details of fastening and securing the assembly unit 300 to the anchor will be described later.
In the embodiments of FIGS. 2A-2D and 3A-3D, the base unit 100 may be formed from rubber, plastic or polymer materials, e.g., polyurethane, ABS, thermoplastic rubber, EVA, PVC, BPU, etc., and combinations thereof. In other embodiments, the base unit 100 may be formed from leather, cork or other natural or organic materials, or from combinations of these materials with rubber, plastic and/or polymer materials. In some embodiments, the base unit 100 may be formed by molding, such as injection molding, or by 3D printing, or other suitable techniques. In yet other embodiments, some components of the base unit, such as the cleat unit or portions thereof, may be formed from metallic materials or from different rubber, plastic or polymer materials having greater rigidity and hardness than the rest of the base unit. Suitable materials for the cleat unit are preferably, but not limited to metallic materials, with a wide range of metallic materials, from stainless steel to copper, that can be used to form the cleat unit. In some embodiments, the cleat unit may be formed by molding, such as injection molding, or by 3D printing, for example, using Markforged® 3D printers with stainless steel filaments or using similar devices.
The Upper Cover Unit
Embodiments of the upper cover unit 200, which is constructed to be releasably attachable to the base unit 100, are described herein below with reference to FIGS. 4A-4B, which are respective side view and front view of an exemplary upper cover unit 200 of the present invention, before it is attached to a base unit 100. The upper cover unit 200, as shown in FIG. 4A, comprises an outer surface, an opposing inner surface, a lower edge forming a lower periphery 200a and an upper edge 200b that forms an upper periphery of the upper cover unit 200.
The upper cover unit 200 is formed to include portions that complement and conform to the shape and structure of portions of the base unit 100 so as to facilitate coupling/attachment between the upper cover unit and the base unit. As shown in FIG. 4A, the upper cover unit 200 comprises a front portion 220, a rear portion 260 and a middle portion 240 provided between the front portion 220 and the rear portion 260. In the illustrative embodiment of FIG. 4A, the upper cover unit 200 is integrally formed or molded as a single piece from the same material throughout the upper cover unit. In other embodiments, the upper cover unit 200 may be formed from different materials in different locations of the upper cover unit. Suitable materials for the upper cover unit are preferably resilient and stretchable materials which include, but are not limited to, resin, polymer materials, such as rubber, plastic, neoprene, knit fabric materials, leather, and faux leather. For example, elastomeric resin such as Flexible 80A manufactured by Formlabs or NinjaFlex® filaments manufactured by NinjaTek/Fenner, Inc. may be used for forming the upper cover unit 200. However, in other embodiments, the upper cover unit 200 may be formed from multiple pieces fused or connected together using suitable methods, including stitching, use of adhesives, use of fasteners, etc., and the individual pieces may be formed from the same material or from different materials. For example, in some examples, the lower area, including the engaging groove 280 described below, may be formed from more rigid materials, such as plastics, resins, polymers, rubber, etc., and the remaining portion of the upper cover unit 200 that covers a user's foot may be formed from more flexible materials than the lower area, such as neoprene, fabric materials, leather, faux leather, and other materials.
In some embodiments, the upper cover unit 200 is manufactured using injection molding and/or 3D printing techniques. Other suitable manufacturing techniques may be used instead or in addition to injection molding and/or 3D printing. In the embodiments of the upper cover unit 200 that is formed from multiple pieces connected together, different pieces may be manufactured using the same techniques or using different techniques.
As shown in FIG. 3A, the engaging groove 280 is formed along the peripheral edge of the upper cover unit 200. The engaging groove 280 is recessed inwardly toward the interior area relative to the peripheral edge of the upper cover unit 200 and forms a channel around at least a portion of the periphery of the upper cover unit 200. Similar to the engaging groove 180 of the base unit 100, the engaging groove 280 of the upper cover unit 200 is horizontally oriented and extends along the front portion 220 and in the rear portion 260. In the illustrative embodiment of FIG. 3A, the engaging groove 280 does not extend along the middle portion 240 of the upper cover unit 200 or includes a break on each side of the middle portion 240. The break in the engaging cover 280 allows the assembly unit 300 to access and extend into the middle portion 240 so as to secure the upper cover unit 200 to the base unit 100. However, in other embodiments, the engaging groove 280 may extend along the entire or substantially entire periphery of the upper cover unit 200 or along a larger or smaller portion of the periphery, with the assembly unit 300 connecting to the base unit 100 in a modified manner as needed.
As can be seen from FIGS. 4A-4B, an outer or exterior surface of the engaging groove 280 forms the channel or recess around at least a portion of the periphery. The opposing interior surface of the engaging groove 280 has a corresponding shape and forms a corresponding projection around the at least a portion of the periphery on the interior of the upper cover unit 200. In this way, when the upper cover unit 200 is assembled with the base unit 100, the lower portion of the upper cover unit 200 is fitted over the upper portion of the base unit 100 and the engaging groove 280 of the upper cover unit is fitted within the engaging groove 180 of the base unit 100 so that the corresponding projection of the engaging groove 280 on the interior surface extends within the engaging groove 180, i.e., the engaging groove 280 of the upper cover unit overlaps with and rests within the engaging groove 180 of the base unit.
The engaging groove 280 is constructed in a corresponding location of the upper cover unit 200 to allow for engagement with the engaging groove 180 of the base unit 100. The engaging groove 280 is shaped so as to complement and cooperate with the engaging groove 180 of the base unit 100 for attaching the upper cover 200 to the base unit 100 to form the shoe assembly. Specifically, the cross-sectional shape, width and depth of the engaging groove 280 is selected so that the corresponding projection formed by the engaging groove 280 on the interior surface of the upper cover unit 200 can be inserted into the engaging groove 180 in the base unit 100, and in some embodiments, the corresponding projection formed by the engaging groove 280 on the interior surface may be configured so as to snap fit into the engaging groove 180 of the base unit 100.
Specifically, in the embodiment of FIG. 4A, the middle portion 240 of the upper cover unit 200 has a cutout on each side, i.e., on a medial side (or arch side) and on a lateral side, of the upper cover unit. The cutout forms a break, i.e., discontinuity or interruption, in the engaging groove 280 of the upper cover unit 200, which is otherwise substantially continuous around the periphery of the upper cover unit, i.e., around the front and rear portions 220, 260. As shown in FIG. 4A, the cutout has two edges, a front edge 241 and a rear edge 242. The positions of the front and rear edges 241 and 242 of the cutout corresponds to the locations of the guides 183 and 184 of the base unit 100, respectively. Although not visible in FIG. 4A, front and rear edges of a cutout on the opposing side of the upper cover unit correspond to the locations of the guides 181 and 182 of the base unit 100, respectively.
FIG. 4B shows a front view of the upper cover unit 200. As shown in FIG. 4B, a channel or passage formed by the engaging groove 280 of the upper cover unit 200 may be rod-shaped or cylindrical in cross-section so as to allow a tube or cable to pass therethrough. Specifically, the passage or channel formed by the engaging groove 280 of the upper cover unit 200 has a “C”-shaped or a “2”-shaped cross-section. However, the passage or channel formed by the engaging groove 280 in other embodiments may have a different, non-circular shape, e.g., rectangular or square cross-section, as long as the engaging groove 280 is capable of fitting into the engaging groove 180 of the base unit 100 and of maintaining the engagement or coupling with the engaging groove 180 of the base unit 100.
Although the upper cover unit 200 of the exemplary embodiment in FIGS. 4A-4B is transparent or translucent, it is contemplated that the color and texture of the upper cover unit can be varied, depending on the desired appearance. For examiner, the material of the upper cover unit may be wholly or partially transparent or may be opaque of a desired color. In addition, as mentioned herein above, the material of the upper cover unit can be formed uniformly of the same material or can be formed from different materials. Moreover, the shape/appearance of the upper cover unit 200 shown in FIGS. 4A-4B is illustrative and can be changed depending on a wearer's preference. For example, in some embodiments, the upper cover unit 200 may cover a whole foot of a user in some embodiments and in others may cover only a portion of the foot. In yet other embodiments, fasteners, such as eyelets, loops, laces, zippers or hook and loop (Velcro®), may be incorporated in the upper cover unit 200.
The Assembly Unit
In order to assemble base unit 100 with the upper cover unit 200, the engaging grooves 180, 280 of the base unit 100 and the upper cover unit 200 are overlapped with one another and the engaging groove 280 is engaged with the engaging groove 180 by inserting projection formed on the interior surface of the engaging groove 280 into the engaging groove 180. As discussed herein above, in some embodiments, the projection formed on the interior surface of the engaging groove 280 of the upper cover unit 200 may snap into the engaging groove 180 of the base unit 180.
After the upper cover unit 200 is attached to or engaged with the base unit 100 by engaging the respective engaging grooves 280, 180 with one another, the assembly unit 300 is applied to further fasten and secure the attachment of the upper cover unit 200 to the base unit 100. FIGS. 5A and 5B show application of the assembly unit 300 to the assembled upper cover unit 200 and base unit 100.
In the embodiments as shown in FIGS. 5A and 5B, the assembly unit 300 comprises a fastening cord 340, such as the string, cable or tether described above or any other elongated flexible member, and at least one retaining member 320, such as at least one tube 320, with the fastening cord 340 being threaded through the tube 320. The retaining member 320 is configured to fit into the engaging groove 280 and functions to retain the fastening cord 340 within the engaging groove 280. As discussed above, the fastening cord 340 is used for tightening and tensioning the assembly unit 300 to secure the upper cover unit 200 to the base unit 100 so as to prevent disengagement during wear.
In the embodiment of FIGS. 5A and 5B, the retaining member 320 is formed as an elongated hollow tube, and more specifically, the tube 320 has an elongated annular hollow body with a central cavity. The tube 320 includes first and second open ends 320a and 320b for passing the fastening cord 340 through the central cavity.
The tube 320 can be formed by injection molding and/or 3D printing techniques, or other conventional processes. The tube 320 can also be constructed from plastic, resin, elastomeric resin, such as Flexible 80A, epoxy, polymers, silicone, silicon, Thermoplastic Polyurethanes (TPU), such as Cheetah® flexible TPU manufactured by NinjaTek/Fenner Inc. and/or other transparent or non-transparent material.
In the embodiments as shown in the above FIGS. 5A and 5B, the tube 320 has a length substantially corresponding to the length of the engaging grooves 180, 280 of the forefoot portion 120 of the base unit 100 and the upper cover unit 200 and is capable of fitting into the engaging groove 280 of the upper cover unit 200 and wrapping around the engaging groove 280 of the forefoot portion 120. As illustrated in the embodiments of FIGS. 5A and 5B, the length of the tube 320 can be slightly longer than the length of the engaging groove 280 in the forefoot portion 120 of the base unit. However, in other embodiments, the length of the tube 320 may be equal to or be shorter than the length of the engaging groove 280 in the forefoot portion 120 of the base unit.
The fastening cord (string, cable, tether, etc.) 340, as shown in the above FIGS. 5A and 5B, is threaded through the central cavity of the tube 320 either before or after the tube 320 is inserted into the engaging groove 280 of the upper cover unit 200. Opposing free ends of the fastening cord 340 extend through the openings 320a, 320b in the tube 320 and are used to connect to and wrap around the anchor 190 on the base unit 100. By wrapping the free ends of the fastening cord 340 around the anchor 190, the fastening cord 340 can be tightened or loosened as needed, by pulling or releasing the opposing free ends, and can be secured to the anchor 190 by suitable methods, such as knot(s), fasteners, etc. In this way, the assembly unit 300 including the tube 320 and the fastening cord 340 cooperates with the engaging grooves 180 and 280 and the anchor 190 to further secure the attachment of the upper cover unit 200 and the base unit 100.
In the embodiment of FIGS. 5A-5B, the fastening cord 340 can be elastic or non-elastic and is preferably, strong and thin so it can be easily tied into a knot and holds well and does not slip when knotted. As shown, the fastening cord 340 is movable and can be free flowing within the central cavity of the tube 320. In another embodiment, the fastening cord 340 can be firmly attached to the central cavity of the tube 320 and is not movable with respect to the tube 320. In some embodiments, the fastening cord includes one or more loops or other type of fasteners at each end configured to engage with the anchor 190. In an illustrative embodiment of a fastening cord with one or more loops, when the fastening cord 340 is attached to the anchor, the one or more loops are engaged with the one or more arms or hooks of the anchor. In some embodiments, the fastening cord includes multiple loops adjacent to each end spaced at different positions on the fastening cord so as to allow for variations in the amount of tightening.
In certain embodiments, the assembly unit 300 includes two retaining members 320, one for passing through the engaging groove 280 in the forefoot portion and another one for passing through the engaging groove 280 in the heel portion of the upper cover member. In addition, as mentioned above, the fastening cord 340 may include a single cord that passes through both of the retaining members 320 or may include two separate cords, one for passing through the retaining member 320 engaged with the forefoot portion and one for passing through the retaining member 320 engaged with the heel portion.
Although the illustrative embodiment of FIGS. 4A and 4B uses a plastic tube 320 as the retaining member and a string 340 as the fastening cord, it is understood that other structures may be used instead of the tube and the string. For example, the tube 320 may have a different shape, and have a much smaller central cavity therethrough, and the fastening cord 340 may include a cable, a lanyard, tape, rope, wire or any other suitable cord-like structure that can be fastened to the anchor 190. Moreover, in some embodiments, the retaining member 320 and the fastening cord may be permanently attached to one another, such as by embedding the fastening cord 340 into the retaining member 320, thus eliminating a central cavity in the retaining member, or by attaching fastening cord sections to each side of the retaining member using suitable attachment means or embedding methods. As mentioned above, although the fastening cord 340 of the illustrative assembly attaches to the anchor 190 by wrapping around the anchor and knotting the cord, in other embodiments, fasteners may be used on the fastening cord 340 to attach the cord to the anchor or corresponding fastening portions may be provided on the cord 340 and on the base unit 100, e.g., on the outsole of the midfoot, for attachment of the cord 340 to the base unit. In certain embodiments, the fastening cord 340 may also have an adjustable length so as to allow of tightening (and loosening) of the cord 340 to the base unit 100 by adjusting the length of the cord 340.
In the illustrative embodiments of FIGS. 5A and 5B, the retaining members 320 are provided separately from the upper cover unit 200 and are inserted into the engaging groove 280 of the upper cover unit 200. However, in other embodiments, the retaining members 320 may be integrated into the upper cover unit by forming a covered channel, or a partially covered channel, instead of the open recess or channel of the engaging groove 280, with the covered channel having open ends for insertion of the fastening cord. In yet other embodiments, the retaining members may be eliminated altogether and a plurality of fastening cords may be permanently attached to the upper cover unit 200 at predetermined areas of the engaging groove 280 or adjacent to the engaging groove 280. For example, four fastening cords may be permanently attached or integrated into the upper cover unit 200, with each of the fastening cords extending from an end of the engaging groove 280, adjacent the middle portion of the upper or extending from an area near the end of the engaging groove 280.
Moreover, although the illustrative examples shown and described above assemble the base unit 100 to the upper cover unit 200 by inserting the engaging groove 280 of the upper cover unit 200 into the engaging groove 180 of the base unit, in other embodiments, the shoe assembly may be modified so that the engaging groove 180 of the base unit 100 is inserted into the engaging groove 280 of the upper cover unit 200. In such alternative embodiments, the assembly unit 300 may then be inserted into the engaging groove 180 of the base unit 100, which would be disposed inside and overlapping with the engaging groove 280 of the upper cover unit 200.
Exemplary Method of Assembly
An exemplary assembly method for securing the attachment of the upper cover unit 200 to the base unit 100 using the assembly unit 300 will be described below.
First, the upper cover unit 200 is aligned with and placed on the base unit 100 so that the forefoot, midfoot and heel portions thereof are aligned, and the engaging groove 280 of the upper cover unit 200 is aligned to overlap with the engaging groove 180 of the base unit 100 and pressed into the engaging groove 180. As discussed above, in some embodiments, the engaging groove 280 is configured to snap fit into the engaging groove 180 of the base unit so as to prevent disengagement.
Second, the fastening cord 340, e.g., string 340, is passed through the longitudinal cavity in the retaining member 320 so that opposing ends of the fastening cord 340 extend from the opposing openings in the retaining member 320. Third, the retaining member 320 is inserted into the channel formed by the engaging groove 280 in the forefoot portion of the upper cover unit 200.
Fourth, the free ends of the fastening cord 340 are passed through the guides 182, 184 in the base unit 100 toward the anchor 190 and wrapped around the anchor 190 to tighten the forefoot portion of the upper cover unit 200 to the forefoot portion of the base unit 100. Before or after the fourth step, the cord 340 can be pulled by the user at the two free ends to make the tube 320 tighten against the engaging groove 280. In this way, the upper cover unit 200 is forced to fit snuggly/tightly against the base unit 100. After two opposite free ends of the cord 340 are wrapped around the anchor 190, they can be fastened to the anchor 190 using knots or fastener(s). If the opposite ends of the cord 340 include loops, the loops can be engaged with the arms or hooks of the anchor 190 so as to attach the cord 340 to the anchor 190. In the embodiments as shown in FIGS. 5A and 5B, the cord 340 is fastened to the X-shape anchor 190 by tying a knot, in order to secure the tight and snug fit of the upper cover unit 200 to the base unit 100. The upper cover unit 200 and the base unit 100 are thus secured to one another and any breaks between them are concealed by tightening and fastening the assembly unit 300.
The above FIGS. 5A and 5B are examples showing the method of assembly around the forefoot portion. The same assembly method can be performed in the heel portion of the upper cover unit 200 and the base unit 100 using a second retaining member 320 and either the remaining portion of the fastening cord 340, i.e., one or both of the free ends of the cord, or a separate fastening cord 340. Applying the assembly unit 300 to the heel portion to secure the attachment of the upper cover unit 200 and the base unit 100 in the heel portion is similar to the forefoot portion.
Specifically, the assembly unit 300 is fitted into and wrapped around the engaging groove 280 which overlaps with the engaging groove 180 in the heel portion of the upper cover unit 200 and the base unit 100. The user then pulls the opposite ends of the cord 340 of the assembly unit 300 to tighten the engagement of the upper cover unit 200 and the base unit in the heel portion. The cord 340 passes through the retaining member 320 engaged with the engaging groove 280 in the heel portion 260 and exits, at guides 181 and 183, such that the cord 340 can be wrapped around the anchor 190 and be tightened and fastened to the anchor 190.
In this way, the upper cover unit 200 can be attached to the base unit 100 via corresponding engaging grooves (180, 280) included in the upper cover unit 200 and the base unit 100 and the attachment of the upper cover unit 200 to the base unit 100 is further secured by wrapping the assembly unit 300 and securing the opposite two ends of the cord 340 to the anchor 190.
There are many known ways to secure the opposite two ends of the cord 340 to the anchor 190. In the present embodiment, a knot that can be tied quickly and untied easily. In other embodiments, loops may be used on the ends of the cord for engagement with the anchor. Alternatively, secure fasteners that can be used for attaching and securing the ends of the cord 340 to the anchor.
OTHER EMBODIMENTS
An alternative version of an upper cover unit 1200, used with an assembly unit 400, is shown in the following FIGS. 6A-6D. In this exemplary embodiment, the upper cover unit 1200 is used together with the assembly unit 400 in the heel portion of the upper cover unit 200. The upper cover unit 1200 may be used to engage with the base unit 100 of FIGS. 2A-2D and 3A-3D described above. Other base units, similar to those shown in this application, may be designed for use with the upper cover unit 1200 of FIGS. 6A-6D.
As illustrated in 6A-6D, the upper cover unit 1200 of this embodiment includes a heel extension 1261 in the heel portion 1260 of the upper cover unit 1200. The heel extension 1261 extends downwardly from the lower edge of the upper portion of the upper cover unit, which may or may not include a groove or channel formed therein similar to the engaging groove 280 shown in the other embodiments and described above. The heel extension 1261 may be integrally formed with the rest of the upper cover unit 1200, as shown in FIGS. 6A-6D, or may be formed separately and attached by suitable means, e.g., gluing, sewing, heat pressing, etc., and may be formed from the same or different materials as the rest of the upper cover unit 200. In the illustrative embodiment of FIGS. 6A-6C, the heel extension 1261 comprises a plurality of holes 1261a (through openings) located around a lower edge of the heel extension 1261. The positioning and number of the holes 1261a around the heel extension 1261 is not limited to those shown in FIGS. 6A-6C and may be adjusted as needed based on the construction of the assembly unit 400 and corresponding construction of the base unit and the position of the engaging groove 180 in the base unit. In some embodiments, the holes 1261a may be omitted altogether, as shown in FIG. 6D.
The assembly unit 400, which is shown in FIG. 6C, when assembled together with the upper cover unit 1200, is attached to the inner surface of the heel extension 1261, i.e., the surface of the heel extension facing inwardly into the upper cover unit, and extends along at least a portion of the length of the heel extension 1261, as shown in FIG. 6D. The attachment of the assembly unit 400 to the heel extension 1261 is preferably secure and/or permanent, i.e., not detachable or removable. The plurality of holes 1261a on the heel extension 1261 can be used to attach the assembly unit 400 to the heel extension 1261 of the upper cover unit 1200 by sewing or other suitable attachment methods. In other embodiments, other methods of attachment of the assembly unit 400 to the heel extension 1261 may be used, including using adhesive(s), tape, suitable metallic or plastic fasteners, heat pressing, screwing, interlocking, etc. In other embodiments, the assembly unit 400 may be releasably attached to the heel extension 1261 using fasteners, e.g., snap fasteners, zipper(s), hook and loop fasteners, etc. or any other suitable means.
As illustrated in FIGS. 6C-6D, the assembly unit 400 comprises an outer tube 420 and an inner tube 440 extending inside and through the outer tube 420. Specifically, the outer tube 420 comprises an elongated channel for receiving and retaining the inner tube 440 therein. In the illustrative example of FIG. 6C, the outer tube 420 has a square or rectangular cross-section while the inner tube 440 has a circular cross-section. However, the cross-section of the outer tube 420, and the external cross-section of the assembly unit 400 as a whole, may be changed depending on the cross-section of the engaging groove 180 in the base unit to enable releasable coupling and retaining of this coupling between the assembly unit 400 and the base unit as described in more detail below.
In the illustrative embodiment of FIGS. 6C-6D, the inner tube 440 is enclosed or surrounded by the outer tube 420 and is fully or substantially fully covered by the outer tube 420 except for the openings in the opposing ends thereof. However, in other embodiments, the inner tube 440 can be partially covered by the outer tube 420, but the coverage should be sufficient for the assembly unit 400 to retain the coupling between the base unit and the assembly unit 400 when the upper cover unit is assembled together with the base unit. The outer tube 420 is formed from a polymer or resin material that has sufficient flexibility and malleability to bend around the heel portion and along the length of the heel extension 1261 and in some embodiments, the outer tube 420 has sufficient plasticity to retain its shape once a desired shape is achieved and has sufficient stiffness to protect the inner tube 440. Suitable materials for the outer tube include, but are not limited to, hardened plastics and certain plastics such as ABS, polycarbonate, polyphenylsulfone (PPSU), and ultra high molecular weight polyethylene (UHMW) that have outstanding toughness. The cross-section of the outer tube 420 preferably conforms to the cross-section of the engaging groove 180 in the heel portion of the base unit with which the upper cover unit 1200 and the assembly unit 400 are to be used. The inner tube 440 may be formed from the same materials as the tube 320 of the assembly in FIGS. 4A-4B, and in some embodiments, maybe made from plastic/polymer or rubber materials.
Although in the embodiments of FIGS. 6C-6D, the assembly unit 400 includes an inner tube and an outer tube with a channel therethrough, in other embodiments, the construction of the assembly unit 400 may be modified without reducing its functionality in assembling the upper cover unit 1200 together with the base unit. For example, in some embodiments, the inner tube 440 may have a solid, instead of a hollow construction, so that no channel is formed therethrough, and in other embodiments, the channel in the inner tube 440 may only pass through a portion of the inner tube 440. In yet other embodiments, the assembly unit 400 may be formed as a single tube or elongated rod-like element, without a separate inner tube, and in some embodiments, the single tube of the assembly unit 400 may have a solid construction, as long as the tube has sufficient flexibility for insertion into the engaging groove 180, or may have a channel therethrough. In yet other embodiments, the assembly unit 400 may include a plurality of tubes or rods-shaped structures having solid or hollow construction, with each of the tubes/rods to be attached along a portion of the length of the heel extension 1261 with predetermined spaces between adjacent tubes/rods so as to provide desired flexibility where needed while maintaining secure coupling.
As mentioned herein above and as shown in FIG. 6D, the assembly unit 400 is attached to the inner surface of the heel extension 1261 of the heel portion 1260 of the upper cover unit 1200, such as by sewing, gluing, taping or otherwise connecting the outer tube 420 to the inner surface of the heel extension 1261. When the upper cover unit 1200, with the assembly unit 400 attached thereto, is assembled with the base unit (e.g., base unit of FIGS. 2A-D, or of FIGS. 2A-D), the upper cover unit 1200 is placed on top of the base unit with the heel extension 1261 extending over the heel portion of the base unit so as to cover and overlap with at least an upper portion of the heel portion of the base unit. The assembly unit 400, attached to the inner surface of the heel extension 1261, is then inserted into the engaging groove (e.g., engaging grooved 180 in FIGS. 2A-2D) in the heel portion of the base unit so as to engage with the engaging groove 180 and to require a certain force to be applied in order to remove the assembly unit 400 from the engaging groove 180. Specifically, in this embodiment, the assembly unit 400 is constructed to substantially conform in shape to the channel formed by the engaging groove 180 in the heel portion of the base unit, and in the illustrative embodiment of FIGS. 6C-6D, the shape and dimensions, e.g., size, thickness, diameter, length, etc., of the outer tube 420 of the assembly unit 400 are selected so that outer tube 420 can be inserted into the channel formed by the engaging groove 180 and preferably, snap fitted into the channel of the engaging groove 180. In the embodiment shown in FIGS. 6C-6D, the cross-section of the outer tube 420 is substantially square or rectangular, but in other embodiments, the cross-section of the outer tube 420 is not limited to the square/rectangular shape and it can be modified to have any suitable shape so as to complement and cooperate with the engaging groove of the base unit.
With this configuration, by engaging and coupling the assembly unit 400 with the engaging groove 180 of the base unit, the upper cover unit 1200 and the base unit 100 can be attached and secured to each other. In addition, the assembly unit 400 provides sealing to the interface between the upper cover unit and the base unit, thus providing desired protection against weather elements, while allowing the upper cover unit to be attached to and detached from the base unit and to be exchanged for a different upper cover unit.
As mentioned above, the construction of the assembly unit 400 may be varied so that for example, the assembly unit may omit the inner tube and only include an outer tube(s) or a rod-shaped element(s). When the assembly unit 400 includes a channel therethrough, as shown in FIGS. 6C-6D, the channel may be used for passing a cord, string, wire, tether or other similar device therethrough, and the ends of the cord, string, wire, tether or other similar device can then be secured to an anchor or similar structure, as described above with respect to FIGS. 2A-2D and 5A-5B, in order to provide additional security against detachment of the upper cover unit 1200 from the base unit 100, 600. This feature is optional and may be omitted, and in some embodiments, the assembly unit 400 may have a solid construction without a through channel. In yet other embodiments, a separate assembly unit 400 may be omitted and instead, the heel extension 1261 may include a projection on its inner surface (with or without a channel therethrough) that conforms in shape and size to the shape and size of the engaging groove in the base unit so that the projection on the heel extension can be snapped into or fitted into the engaging groove in the base unit. In some embodiments, the projection on the inner surface of the heel extension 1261 may be formed from a different material than the heel extension 1261 or may be coated or enclosed, or partially coated or enclosed, by a different material, such as a material with higher friction coefficient that would prevent movement or slipping of the projection within the engaging groove 180 of the base unit.
Although in some embodiments described above, the assembly unit 400 is inserted into the engaging groove 180 of the base unit, in other embodiments, the upper cover unit 1200 engages with the base unit by engaging the engaging groove of the upper cover unit 1200 with the engaging groove 180 of the base unit, similar to the assembly of FIGS. 1A-1B. The assembly unit 400 attached or provided on the inner surface of the heel extension 1261 is then used for sealing the space between the heel extension 1261 and the heel of the base unit. In this assembly, the assembly unit 400 would extend in the space between the heel extension 1261 and the heel of the base unit, below the engaging groove 180 engaged with the engaging groove of the upper cover unit 1200. This results in better waterproofing of the resulting shoe assembly while also preventing disengagement of the upper cover unit from the base unit.
In FIGS. 6A-6D, the upper cover unit 1200 has a heel extension 1261 in the heel portion thereof while the forefoot portion includes a groove similar to the embodiments in FIGS. 4A-4B. In other embodiments, the upper cover unit includes a forefoot extension that extends downwardly from the lower edge of the forefoot portion of the upper cover unit, and a second assembly unit (not shown) similar to the assembly unit 400 described above may be provided or a projection on the inner surface of the forefoot extension may be formed. The assembly method for assembling the forefoot portion having the forefoot extension with the second assembly unit or a projection and the forefoot portion of the base unit is similar or substantially the same as the method described above with respect to the heel portion of the shoe, and is therefore omitted.
Another Alternative Version of the Upper Cover Unit
FIGS. 7A and 7B show another variation of an upper cover unit 600 of the shoe assembly. Specifically, FIGS. 7A and 7B provide perspective views of the alternative embodiment of the upper cover unit 600 of the shoe assembly before a base unit 100 is attached thereto. As shown in FIGS. 7A and 7B, the upper cover unit 600 includes an upper portion covering a user's foot and a lower extension 661 extending downwardly from a lower peripheral edge of the upper portion. The construction of the upper cover unit 600 of FIGS. 7A and 7B is similar to the construction of the upper cover unit 1200 of FIGS. 6A-6D, but the lower extension 661 in this embodiment extends around the rear portion 660, the middle portion 640 and at least a part of the front portion 620 of the upper cover unit 600. As in the embodiment of FIGS. 6A-6D, the upper cover unit 600 of the present invention can be used with the fastening assembly 400 shown in FIGS. 6C and 6D, wherein the fastening assembly is attached to the inner surface of the lower extension 661. By providing a lower extension 661 that extends around the entire or nearly the entire periphery of the shoe upper of the upper cover unit 600, the fastening assembly 400 can provide a continuous seal around the periphery of the shoe assembly and at the interface between the upper cover unit 600 and the base unit 100.
As shown, the height of the lower extension 661 is the greatest in the rear portion 660 and gradually decreases in the middle portion 640 and the front portion 620. As in the upper cover unit 1200, the lower extension 661 includes a plurality of through openings 661a, which may be used for attaching the assembly unit 400 shown in FIGS. 6C and 6D. In this embodiment, the assembly unit 400 shown in FIGS. 6C and 6D may be used together with the upper cover unit 600 in a similar manner as described above, and thus, detailed description thereof is omitted.
According to one embodiment of the present disclosure, the upper cover unit 600 is made of any highly elastic materials, for example, NinjaFlex® fibers or leather, and can be worn directly over the sock or bare foot of the user. Other polymer, resin, rubber, fabric and organic materials may be used for the upper cover unit 600. In some embodiments, the upper cover unit 600 may be formed by molding, such as injection molding, or by 3D printing, using suitable 3D filaments, such as Cheetah® flexible Thermoplastic Polyurethane (TPU) filaments, etc.
The upper cover unit 600 shown in the illustrative embodiment of FIGS. 7A and 7B includes an engaging groove 680 extending between the upper portion of the upper cover unit 600 and the lower extension 661, i.e., just above the lower extension. The engaging groove 680 is recessed inwardly toward the interior area relative to the exterior surface of the upper cover unit and forms a continuous channel or a multiple discontinuous channels along the lower edge of the base unit. The engaging groove 680 is substantially horizontally oriented and extends substantially along a forefoot portion and a heel portion of the upper cover unit 600. Specifically, in this exemplary embodiment, the depth of the engaging groove 680 gradually decreases in the middle portion 640 of the upper cover unit 600 and creates a discontinuity in the channel of the engaging groove in the middle portion 640.
The upper cover unit 600 of this embodiment may be used with the base unit 100 shown in FIGS. 2A-2D or 3A-3D. The engaging groove 680 may be used for engaging with and cooperate with the engaging groove 180 of the base unit 100 shown in FIGS. 2A-2D or 3A-3D, for attaching the upper cover unit 600 to the base unit 100 to form the shoe assembly. Further, the attachment between the upper cover unit 600 and the upper cover unit 600 can be secured by applying the assembly unit 300 to the engaging groove 280 of an upper cover unit 600 and thereafter fastening the fastening cord to the cleat or anchor on the base unit 100. These assembly methods have been described in detail above and are thus omitted here.
Although preferred embodiments of the invention have been described in the foregoing detailed description and illustrated in the accompanying drawings, it will be understood that the invention is not limited to the embodiments disclosed but is capable of numerous rearrangements, modifications and substitutions of parts and elements without departing from the spirit of the invention. Accordingly, the present invention is intended to encompass such rearrangements, modifications and substitutions of parts or elements as fall within the scope of the invention.
With the above-described construction of the shoe assembly with the detachable shoe cover (upper cover unit), the user is able to customize their shoes according to a variety of designs, functions, and shapes. By combining different styles of an upper cover unit and a base unit, variety of shoes such as sporting shoes, sneakers, dress shoes, boots, work boots, or any other types of footwear can be obtained. As such, a shoe style can be quickly and easily modified according to a user's preferences and needs.
Moreover, because the shoe cover (upper cover unit) can be easily removed from the base unit and in some embodiments, the upper cover unit is constructed of plastic/rubber/polymer materials, washing the shoe assembly is easily accomplished. Even when portions of the shoe assembly are made from leather, fabrics, and other materials which are typically more difficult to clean, the ability to disassemble the base unit and the upper cover unit allows the user easier access to the interior of the shoe making it easier to clean. In an event that the interior of the shoe assembly is exposed to water, the user can easily disassemble the base unit and the upper cover unit to allow them to dry faster and more efficiently. If shoe's upper cover unit is soiled or permanently damaged, the shoe's upper cover unit can be inexpensively replaced.
Moreover, the materials of the shoe can be completely recycled. The scraps and waste can eventually be used to make new products, which makes manufacture of the shoe assembly less inexpensive.
As described above, the shoe assembly of the present invention has many advantages for the user stylistically and functionally.
LEGEND
- Elements and components in the figures of the present application are listed below:
100 base unit
120 forefoot portion
140 midfoot portion
160 heel portion
170 cleat unit
170
a top surface of cleat unit
170
b bottom surface of cleat unit
1701 first side extension
1702 second side extension
1703 third side extension
1704 fourth side extension
180 engaging groove of base unit
181-184 guides
190 anchor
200 upper cover unit
220 front portion
240 middle portion
241-242 front and rear edges of cutout
260 rear portion
280 engaging groove of upper cover unit
300 assembly unit
320 retaining member/tube
320
a first open end
320
b second open end
340 fastening cord/string
400 assembly unit
420 outer tube
440 inner tube
600 upper cover unit
620 front portion
640 middle portion
660 rear portion
661 lower extension
661
a through openings
680 engaging groove of upper cover unit
1200 upper cover unit
1220 front portion
1240 middle portion
1260 rear portion
1261 heel extension
1261
a holes
Patent Application
20240268516
